US9162750B2 - Aircraft propeller blade - Google Patents

Aircraft propeller blade Download PDF

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US9162750B2
US9162750B2 US13/517,410 US201013517410A US9162750B2 US 9162750 B2 US9162750 B2 US 9162750B2 US 201013517410 A US201013517410 A US 201013517410A US 9162750 B2 US9162750 B2 US 9162750B2
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Prior art keywords
blank
fiber
airfoil
profile structure
blade
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US13/517,410
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US20130017093A1 (en
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Dominique Coupe
Bruno Jacques Gerard Dambrine
Jean-Noel Mahieu
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Safran Aircraft Engines SAS
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SNECMA SAS
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Assigned to SAFRAN AIRCRAFT ENGINES reassignment SAFRAN AIRCRAFT ENGINES CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: SNECMA
Assigned to SAFRAN AIRCRAFT ENGINES reassignment SAFRAN AIRCRAFT ENGINES CORRECTIVE ASSIGNMENT TO CORRECT THE COVER SHEET TO REMOVE APPLICATION NOS. 10250419, 10786507, 10786409, 12416418, 12531115, 12996294, 12094637 12416422 PREVIOUSLY RECORDED ON REEL 046479 FRAME 0807. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME. Assignors: SNECMA
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C11/00—Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
    • B64C11/16—Blades
    • B64C11/20—Constructional features
    • B64C11/26—Fabricated blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0025—Producing blades or the like, e.g. blades for turbines, propellers, or wings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/082—Blades, e.g. for helicopters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B29L2031/087—Propellers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments

Definitions

  • the present invention relates to the field of propeller blades for aircraft, such as the blades present on turboprops.
  • Propeller blades for turboprops are generally made of a metal material. Although propeller blades made of metal material present good mechanical strength, they nevertheless present the drawback of being relatively heavy.
  • propeller blades that are lighter, it is known to make propeller blades out of composite material, i.e. by making structural parts out of fiber reinforcement with a resin matrix.
  • the technique generally used consists in forming a stack of preimpregnated unidirectional sheets or plies (draping) that is placed in a mold with the successive plies being given different orientations, prior to compacting and polymerizing in an autoclave.
  • a propeller blade can be made by that technique is described in particular in document U.S. Pat. No. 6,666,651.
  • Document EP 1 526 285 describes a more effective method of fabricating a turbine engine blade out of composite material, the blade being fabricated by three-dimensionally weaving a fiber preform and densifying the preform with an organic matrix. That method makes it possible to obtain blades that present very great mechanical strength, in particular against shocks or impacts, without any risk of delamination. Nevertheless, propeller blades of large dimensions made using that technique still present relatively great weight. Unfortunately, in order to improve the performance of turboprops, in particular in terms of fuel consumption, it is desired to reduce weight.
  • the invention provides an aircraft propeller blade having an airfoil-profile structure that comprises at least one fiber reinforcement obtained by three-dimensional weaving of yarns and densified by a matrix, and a shaping part made of cellular rigid material of determined shape, the reinforcement comprising at least two halves linked together by continuous weaving in the leading edge of the propeller blade, the two halves fitting tightly around said shaping part.
  • the propeller blade of the invention is both lighter in overall weight as a result of having a shaping part made of low density material, and also of great mechanical strength as a result of having a skin made of a composite material structure (fiber reinforcement densified by a matrix).
  • the propeller blade also presents good ability to withstand shocks or impacts since the portion of the fiber reinforcement that constitutes the leading edge presents great cohesion in this location as a result of continuous weaving.
  • the blade of the invention further comprises a beam having a first portion arranged inside the airfoil-profile structure and surrounded at least in part by the shaping part, and a second portion extending outside said structure, said second portion including a blade root at its end.
  • the beam is formed by fiber reinforcement densified by a matrix.
  • the first portion of the beam may include an enlarged portion forming a retaining element for retaining the beam in the airfoil-profile structure.
  • the propeller blade of the invention further comprises a blade root formed by fiber reinforcement densified by a matrix, the fiber reinforcement of the blade root being woven continuously with the fiber reinforcement of the airfoil-profile structure.
  • the two halves of the fiber reinforcement are partially separated by a non-interlinked region that is obtained during the three-dimensional weaving.
  • the two halves of the fiber reinforcement may include at least one stiffener-forming extra thickness on their facing faces.
  • the airfoil-profile structure may in particular comprise carbon fiber reinforcement densified by a carbon matrix.
  • the invention also provides a method of fabricating an aircraft propeller blade, the method comprising at least:
  • the method of the invention further includes making a beam by three-dimensionally weaving a fiber blank and by densifying said blank with a matrix in order to obtain a beam of composite material having fiber reinforcement densified by the matrix, said beam comprising a mast and a blade root, and during shaping of the fiber blank, placing the mast of the beam between the two halves of the fiber blank, said mast being surrounded at least in part by the shaping part.
  • the method may include forming at least one enlarged portion on the mast of the beam, said enlarged portion being made by varying the weight and/or the thread count of the yarns of the blank or by incorporating an insert during three-dimensional weaving.
  • the fiber blank of the beam is woven in the form of a fiber strip, said strip being folded around an insert to form the blade root, a core part of cellular rigid material being inserted between the two folded-together portions of the fiber strip.
  • the fiber blank of the airfoil-profile structure further includes a second portion woven continuously with the first portion of said blank, and after densification, said second portion forms a blade root.
  • the two halves of the fiber blank are separated in part by forming a non-interlinked region during the three-dimensional weaving.
  • the fiber blank is shaped by folding two halves of the fiber blank onto the shaping part.
  • the method may further comprise forming at least one stiffener-forming extra thickness on the facing faces of the two halves of the blank.
  • the invention also provides a turboprop fitted with a propeller blade of the invention.
  • the invention also provides an aircraft fitted with at least one turboprop of the invention.
  • FIG. 1 is a perspective view of an aircraft propeller blade in accordance with an embodiment of the invention
  • FIG. 2 is a perspective view of a turboprop fitted with a plurality of propeller blades of the invention
  • FIG. 3 is a diagrammatic view showing the three-dimensional (3D) weaving of a fiber blank for fabricating the FIG. 1 propeller blade;
  • FIGS. 4A and 4B are fragmentary section views on a larger scale of a set of yarn layers forming the FIG. 3 blank;
  • FIG. 5 is an exploded view showing how the FIG. 1 propeller blade is made
  • FIG. 6 is a weft section view showing an example arrangement of weft yarns in a fiber blank portion corresponding to a blade root portion;
  • FIGS. 7A to 7C show how a beam is made in accordance with an implementation of the invention.
  • FIG. 8 is a section view of the FIG. 1 propeller blade
  • FIG. 9 is an exploded view showing how an aircraft propeller blade is made in accordance with another implementation of the invention.
  • FIG. 10 is a diagrammatic view showing the 3D weaving of a fiber blank for fabricating the FIG. 11 propeller blade;
  • FIG. 11 is a perspective view showing a propeller blade obtained from elements shown in FIG. 9 ;
  • FIG. 12 is a section view of the FIG. 11 propeller blade
  • FIG. 13 is an exploded view showing how an aircraft propeller blade is made in accordance with another implementation of the invention.
  • FIG. 14 is a diagrammatic view showing the 3D weaving of a fiber blank for fabricating the FIG. 15 propeller blade.
  • FIG. 15 is a perspective view showing a propeller blade obtained from the elements shown in FIG. 13 .
  • the invention applies in general to various types of propeller blade used in the engines of aircraft such as airplanes or helicopters.
  • the invention finds an application that is advantageous but not exclusive in propeller blades of large dimensions that, because of their size, present considerable weight and have a significant impact on the overall weight of the engine of the aircraft.
  • FIG. 1 shows a propeller blade 10 for mounting on an airplane turboprop, which propeller blade comprises, in well-known manner, an airfoil-profile structure 20 that is to form the airfoil portion of the blade, a root 30 formed by a thicker portion, e.g. having a bulb-shaped section extended by a tang 32 .
  • the airfoil-profile structure 20 presents, in cross-section, a curved profile of thickness that varies going from its leading edge 20 a to its trailing edge 20 b.
  • the blade 10 is mounted on a rotor 51 of a turboprop 50 by engaging the root 30 in a housing formed in the periphery of the rotor 51 (not shown in FIG. 2 ).
  • FIG. 3 is a diagram showing a fiber blank 100 for forming the fiber preform of the blade airfoil-profile structure.
  • the fiber blank 100 is obtained by 3D weaving performed in known manner on a Jacquard type loom having a bundle of warp yarns 101 or twisted strands in a plurality of layers each comprising several hundreds of yarns, the warp yarns being linked together by weft yarns 102 .
  • the 3D weaving is performed using an “interlock” type weave.
  • interlock type weave is used herein to designate a weave in which layer of weft yarns links together a plurality of layers of warp yarns with all of the yarns in a given weft column presenting the same movement in the weave plane.
  • the fiber blank of the invention may be woven from yarns made of carbon fiber or of ceramic, such as silicon carbide.
  • a line 103 of non-interlinking ( FIG. 3 ) is organized inside the fiber blank between two successive layers of warp yarns, with this extending over a region 104 of non-interlinking ( FIG. 5 ).
  • the non-interlinked region 104 serves to provide a cavity 104 a that enables a shaping part, possibly a beam, to be inserted inside the fiber blank 100 in order to form the preform of the airfoil-profile structure.
  • FIGS. 4A and 4B One way of making the blank 100 with a 3D interlock weave is shown diagrammatically in FIGS. 4A and 4B .
  • FIG. 4A is an enlarged fragmentary view showing two successive warp section planes in a portion of the blank 100 that does not present non-interlinking, i.e. in a region of the blank that does not lie in the non-interlinked region 104
  • FIG. 4B shows two successive warp section planes in a portion of the blank 100 that presents a line 103 of non-interlinking that forms part of the non-interlinked region 104 .
  • the blank 100 has six warp yarn layers 101 extending in the X direction.
  • the six warp yarn layers are linked together by weft yarns T 1 to T 5 .
  • three warp yarn layers 101 forming the set of yarn layers 105 are linked together by two weft yarns T 1 , T 2 , as are the three warp yarn layers forming the set of yarn layers 106 that are linked together by two weft yarns T 4 and T 5 .
  • weft yarns T 1 , T 2 do not extend in the yarn layers 106 and the weft yarns T 4 , T 5 do not extend in the yarn layers 105 ensures that there is a line 103 of non-interlinking that separates the sets of warp yarn layers 105 and 106 from each other.
  • the warp and weft yarns at the boundary of the woven mass are cut away, e.g. by using a jet of water under pressure, in order to extract the blank 100 , which is shown in FIG. 5 as it appears after 3D weaving and before any shaping.
  • the non-interlinked region 104 that was provided during weaving serves to form two halves 110 and 111 that are woven independently of each other and that define the cavity 104 a inside the blank 100 .
  • the cavity 104 a is open to the bottom edge 100 c and to the rear edge 100 b of the blank 100 .
  • the rear edge 100 b of the blank 100 corresponds to the portion that is to form the trailing edge 20 b of the airfoil-profile structure 20 ( FIG. 1 ).
  • the front edge 100 a of the fiber blank 100 connecting together the two halves 110 and 111 and that is to form the leading edge 20 a of the airfoil-profile structure of the propeller blade, does not include any non-interlinking.
  • the airfoil-profile structure of the propeller blade has fiber reinforcement that is uniform in its leading edge, thereby reinforcing its ability to withstand impacts, if any.
  • the fiber blank 100 is shaped to constitute a preform for the airfoil-profile structure by inserting a shaping part of rigid material 140 into the cavity 104 a , which part is constituted in this example by three complementary elements 141 , 142 , and 143 .
  • the part 140 is made of a cellular rigid material, i.e. a material of low density.
  • the shaping part or more precisely in the example described the elements 141 to 143 , may be made by molding or by machining a block of material.
  • the shaping part 140 is of a shape corresponding to the shape of the airfoil-profile structure that is to be made.
  • it in its anterior portion 140 a ( FIG. 1 ) it includes a rounded end suitable for constituting the leading edge 20 a with a radius of curvature that is sufficiently large to obtain good impact resistance and to avoid the appearance of cracks.
  • a beam 150 is also inserted inside the cavity 104 a between the three elements 141 , 142 , and 143 .
  • the beam 150 comprises a mast 151 with first and second enlarged portions 152 and 153 .
  • the first enlarged portion 152 is for acting in a manner described below to form an element for retaining the beam in the fiber reinforcement of the airfoil-profile structure, while the second enlarged portion 153 is for forming the root 30 of the propeller blade 10 ( FIG. 1 ), the portion 154 that is situated between the enlarged portions 152 and 153 serving to form the tang 32 of the blade ( FIG. 1 ).
  • the fiber preform of the airfoil-profile structure is densified.
  • the rear edge 100 b and the bottom edge 100 c of the blank are preferably closed by stitching before performing densification.
  • Densification of the fiber preform consists in filling the pores of the preform, in all or part of its volume, with the material that is to constitute the matrix.
  • the matrix of the composite material constituting the airfoil-profile structure may be obtained in known manner using the liquid technique.
  • the liquid technique consists in impregnating the preform with a liquid composition containing an organic precursor for the material of the matrix.
  • the organic precursor is in the form of a polymer, such as a resin, possibly diluted in a solvent.
  • the preform is placed in a mold suitable for being closed in leaktight manner and having a recess that has the shape of the molded finished part and that may in particular present a shape that is twisted, corresponding to the final shape for the airfoil-profile structure. Thereafter, the mold is closed and the liquid precursor for the matrix (e.g. a resin) is injected throughout its entire recess in order to impregnate all of the fiber portion of the preform.
  • the liquid precursor for the matrix e.g. a resin
  • the precursor is transformed into an organic matrix, i.e. it is polymerized, by performing heat treatment, generally by heating the mold, after eliminating any solvent and curing the polymer, with the preform continuing to be held in the mold that has a shape corresponding to the shape to be given to the airfoil-profile structure.
  • the organic matrix may in particular be obtained from epoxy resins, such as the high-performance epoxy resin sold under the reference PR 520 by the supplier CYTEC, or liquid precursors for carbon or ceramic matrices.
  • the heat treatment consists in pyrolyzing the organic precursor in order to transform the organic matrix into a carbon or ceramic matrix depending on the precursor used and on the pyrolysis conditions.
  • liquid precursors for carbon may be resins having a relatively high coke content, such as phenolic resins
  • liquid precursors for ceramics, in particular SiC may be resins of the polycarbosilane (PCS) type or of the polytitanocarbosilane (PTCS) type, or of the polysilazane (PSZ) type.
  • PCS polycarbosilane
  • PTCS polytitanocarbosilane
  • PSZ polysilazane
  • the fiber preform may be densified by the method known as resin transfer molding (RTM).
  • RTM resin transfer molding
  • the fiber preform including the beam 150 and the elements 141 to 143 making up the shaping part 140 is placed in a mold having the outside shape of the airfoil-profile structure.
  • the shaping piece 140 is made of rigid material and has a shape that corresponds to the shape of the airfoil-profile structure that is to be made, it advantageously acts as a countermold.
  • a thermosetting resin is injected into the inside space defined between the rigid material part and the mold and that includes the fiber preform.
  • a pressure gradient is generally established in this inside space between the location where the resin is injected and orifices for evacuating the resin, for the purpose of controlling and optimizing the manner in which the preform is impregnated by the resin.
  • the resin used may be an epoxy resin.
  • Resins suitable for RTM methods are well known. They preferably present low viscosity so as to facilitate being injected among the fibers.
  • the temperature class and/or the chemical nature of the resin is/are selected as a function of the thermomechanical stresses to which the part is to be subjected.
  • the part After injection and polymerization, the part is unmolded. The part is trimmed in order to remove excess resin, and the chamfers are machined. No other machining is required since, given that the part is molded, it complies with the required dimensions.
  • the cellular rigid material used for making the elements 141 to 143 constituting the shaping part 140 is preferably a material having cells that are closed so as to prevent the resin from penetrating therein, thereby conserving its low density after the fiber preform has been densified.
  • the beam 150 is made of composite material. Like the airfoil-profile structure, a fiber blank is made initially by 3D weaving, e.g. using a 3D interlock weave. During the weaving of the fiber blank of the beam, the first and second enlarged portions 152 and 153 may be obtained by using weft yarns of greater weight and by using additional layers of weft yarns, as shown for example in FIG. 6 .
  • the number of weft yarns goes in this example from four to seven between the portion 154 of the strip of the fiber blank that corresponds to the tang of the propeller blade, and the second enlarged portion 153 of the strip that corresponds to the blade root.
  • weft yarns t 1 , t′ 1 , t′′ 1 that are of differing (increasing) weights.
  • the first enlarged portion 152 corresponding to the retaining element may be made in the same manner.
  • it is also possible to vary the thread count of the warp yarns i.e. the number of yarns per unit length in the weft direction).
  • the first and second enlarged portions 152 and 153 may be obtained by inserting inserts while weaving the strip of the fiber blank for the beam 150 .
  • Such an insert may be made in particular out of titanium or out of the same material as constitutes the matrix of the composite material of the beam.
  • the fiber blank of the beam is densified by an organic matrix that may be deposited by using a liquid technique as described above, and in particular by impregnation and polymerization in a shaping tool or by RTM.
  • FIGS. 7A to 7C show a variant embodiment of the beam of the invention.
  • a fiber blank 160 that is obtained by interlock type three-dimensional weaving, for example.
  • An insert 161 is placed in the center of the strip of the blank 200 ( FIG. 7A ).
  • the strip is then folded in half about the insert 161 with a core part 162 being inserted between the two folded strip portions ( FIG. 7B ).
  • the insert 161 enables an enlarged portion to be formed that is to constitute the blade root.
  • the core part 162 is made of cellular rigid material so as to reduce the overall weight of the beam.
  • the core part may include an enlarged portion 162 a that is to form the retaining element of the beam.
  • a beam 170 is then obtained that has a core of low density and that comprises a mast 171 , a first enlarged portion 172 corresponding to the retaining element of the beam, a portion 173 corresponding to the tang of the propeller blade, and a second enlarged portion 174 corresponding to the root of the blade.
  • a propeller blade 10 is obtained as shown in FIG. 1 that comprises an airfoil-profile structure 20 that is made out of composite material (fiber reinforcement densified with a matrix), a shaping part 140 of cellular rigid material, and a beam 150 of composite material.
  • the first enlarged portion 151 of the beam 150 is engaged between the two elements 142 and 143 of the shaping part 140 ( FIG. 1 ) which are themselves enclosed within the densified airfoil-profile structure 20 .
  • the enlarged portion 151 thus constitutes a (self-locking) retaining element 33 for retaining the airfoil-profile structure on the beam 150 , thereby reinforcing the connection between said structure and the root of the propeller blade. It should be observed that the beam 150 may also be made without a retaining element.
  • FIG. 9 shows another embodiment of an aircraft propeller blade of the invention.
  • a fiber blank 200 is made that corresponds to developing the airfoil-profile structure of the propeller blade.
  • the fiber blank 200 is obtained by 3D weaving, e.g. of the interlock type, between warp yarns 201 or twisted strands arranged in a plurality of layers, each comprising several hundreds of yarns, and weft yarns 202 .
  • 3D weaving e.g. of the interlock type
  • weaving of the blank that is of varying thickness and width, a certain number of warp yarns are not involved in the weaving, thereby making it possible to define the continuously-varying outline and thickness that are desired for the blank 200 .
  • weaving is controlled so as to form extra thickness 203 on one face of the blank.
  • the extra thickness 203 is to constitute a stiff
  • the warp and weft yarns that are not woven are cut away so as to obtain the fiber blank as shown in FIG. 10 .
  • Two elements 241 and 242 made of a cellular rigid material of the same kind as that of the above-described elements 141 to 143 are assembled together to form a shaping part 240 of a determined shape that corresponds to the shape of the airfoil-profile structure that is to be made.
  • the two elements 241 and 242 are disposed on either side of a beam 250 similar to the above-described beam 150 and comprising a mast 251 , a first enlarged portion 252 that is to form an element for retaining the beam in the fiber reinforcement of the airfoil-profile structure, as described below, and a second enlarged portion 253 that is to form the root of the propeller blade.
  • the fiber blank presents two symmetrical halves 210 and 211 that are connected together by continuous weaving in a fold line 200 a that is to form the leading edge of the airfoil-profile structure of the propeller blade.
  • the two elements 241 and 242 of the beam 250 are placed on one of the two halves 210 and 211 , e.g. the half 211 , with the other half that is left free, here the half 210 , then being folded onto the half 211 .
  • the fiber preform of the airfoil-profile structure is then densified using the liquid technique as described above.
  • a propeller blade 40 is then obtained that has an airfoil-profile structure 50 that is made of composite material (fiber reinforcement densified with a matrix), having a leading edge 50 a and a trailing edge 50 b , a shaping part 240 of cellular rigid material, and a beam 250 made of composite material.
  • the first enlarged portion 251 of the beam 250 is engaged between the two elements 241 and 242 of the shaping part 240 , which are themselves tightly fitted in the densified airfoil-profile structure 50 .
  • the enlarged portion 251 thus constitutes a (self-locking) retaining element 63 for retaining the airfoil-profile structure on the beam 250 , thereby reinforcing the connection between said structure and the root of the propeller blade. It should be observed that the beam 150 may also be made without a retaining element.
  • the portion of the beam 250 that extends beyond the airfoil-profile structure 50 comprises a tang 62 extended by a root 60 that is formed by the second enlarged portion 253 of the beam 250 .
  • the extra thickness 203 formed during the weaving of the fiber blank 200 forms two stiffeners 21 a and 21 b arranged on either side of the beam 250 .
  • the number and positions of the stiffeners are not restricted to the stiffeners 21 a and 21 b shown in FIGS. 11 and 12 .
  • other stiffeners may be formed in the airfoil-profile structure.
  • the positions, shapes, and number of stiffeners are defined during weaving of the fiber blank for the airfoil-profile structure, in the manner described above.
  • leading edge 50 a corresponds to the fold line connecting together the two halves 210 and 211 of the fiber blank.
  • the airfoil-profile structure 50 of the propeller blade 40 presents a continuous woven connection in the leading edge so as to reinforce its impact strength.
  • FIG. 13 shows yet another embodiment of an aircraft propeller blade of the invention.
  • a fiber blank 300 is made that comprises, in a single woven part, both a first portion 310 that is to form the airfoil-profile structure of the propeller blade, and also a second portion 312 that is to form the blade root.
  • the fiber blank 300 is obtained by 3D weaving, e.g. of the interlock type, between warp yarns 301 or twisted strands arranged in a plurality of layers each having several hundreds of yarns, and weft yarns 302 .
  • 3D weaving e.g. of the interlock type
  • a certain number of warp yarns are not involved in the weaving, thereby defining the continuously-varying outline and thickness that are desired for the blank 300 .
  • Document EP 1 526 28 describes making a fiber blank for a turbine engine blade by 3D weaving, the blank having a first portion made with a first weave to form a blade airfoil, here corresponding to the first portion 310 that is to form the airfoil-profile structure, and a second portion made with a second weave to form the blade root, here corresponding to the second portion 312 that is to form the blade root.
  • two successive layers of warp yarns are not interlinked inside the fiber blank over a non-interlinked region 304 ( FIG. 13 ) serving to provide a cavity 304 a that enables a shaping part 340 of cellular rigid material to be inserted inside the fiber blank 300 in order to form the preform for the airfoil-profile structure.
  • the second portion 312 of the fiber blank presents an enlarged shape in order to form the blade root.
  • the portion 312 may be obtained by using weft yarns of greater weight and by using additional layers of weft yarns.
  • it is possible to vary the thread count of the warp yarns i.e. the number of yarns per unit length in the weft direction). It is also possible to incorporate an insert during weaving of the fiber blank.
  • the warp and weft yarns at the boundary of the woven mass are cut away, e.g. by a jet of water under pressure in order to extract the blank 300 which is shown in FIG. 13 as it appears after 3D weaving and before any shaping.
  • the non-interlinked region 304 formed during the weaving serves to form two halves 310 and 311 that are woven independently of each other and that define the cavity 304 a inside the blank 300 .
  • the cavity 304 a is open to the rear edge 300 b of the blank 300 that corresponds to the portion that is to form the trailing edge 80 b of the airfoil-profile structure 80 ( FIG. 15 ).
  • the front edge 300 a of the fiber blank 300 connecting together the two halves 310 and 311 and that is to form the leading edge 80 a ( FIG. 15 ) of the airfoil-profile structure of the propeller blade does not include any non-interlinked region.
  • the airfoil-profile structure of the propeller blade includes fiber reinforcement that is uniform in the leading edge in order to increase its strength against possible impacts.
  • the fiber blank 300 is shaped to form a preform of the airfoil-profile structure by inserting a shaping part 340 of cellular rigid material into the cavity 304 a.
  • the fiber preform for the airfoil-profile structure is densified as described above.
  • this produces a propeller blade 70 comprising a single piece of composite material (fiber reinforcement densified by a matrix), with an airfoil-profile structure 80 having a leading edge 80 a and a trailing edge 80 b , a tang 92 , and a root 90 .
  • the shaping part 240 of cellular rigid material is also present inside the airfoil-profile structure.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Woven Fabrics (AREA)
  • Moulding By Coating Moulds (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
US13/517,410 2009-12-21 2010-12-20 Aircraft propeller blade Active 2032-11-24 US9162750B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR0959285A FR2954271B1 (fr) 2009-12-21 2009-12-21 Pale d'helice d'aeronef
FR0959285 2009-12-21
PCT/FR2010/052829 WO2011083250A1 (fr) 2009-12-21 2010-12-20 Pale d'helice d'aeronef

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US20130017093A1 US20130017093A1 (en) 2013-01-17
US9162750B2 true US9162750B2 (en) 2015-10-20

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EP (1) EP2516263B1 (fr)
JP (1) JP5922032B2 (fr)
CN (1) CN102666277B (fr)
BR (1) BR112012015167B1 (fr)
CA (1) CA2784740C (fr)
FR (1) FR2954271B1 (fr)
RU (1) RU2533384C2 (fr)
WO (1) WO2011083250A1 (fr)

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US20160053619A1 (en) * 2011-06-30 2016-02-25 United Technologies Corporation Cmc blade with integral 3d woven platform
US10626884B2 (en) 2016-12-09 2020-04-21 Hamilton Sundstrand Corporation Systems and methods for making airfoils
US10710705B2 (en) 2017-06-28 2020-07-14 General Electric Company Open rotor and airfoil therefor
FR3107719A1 (fr) * 2020-03-02 2021-09-03 Safran Aircraft Engines Texture fibreuse pour aube de turbomachine en matériau composite
US11346363B2 (en) * 2018-04-30 2022-05-31 Raytheon Technologies Corporation Composite airfoil for gas turbine
US11846192B1 (en) 2023-04-21 2023-12-19 General Electric Company Airfoil assembly with a trunnion and spar
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US20160053619A1 (en) * 2011-06-30 2016-02-25 United Technologies Corporation Cmc blade with integral 3d woven platform
US10024173B2 (en) * 2011-06-30 2018-07-17 United Techologies Corporation CMC blade with integral 3D woven platform
US20150013160A1 (en) * 2012-01-25 2015-01-15 Snecma Method for producing a propeller blade from a composite material
US9457435B2 (en) * 2012-01-25 2016-10-04 Snecma Method for producing a propeller blade from a composite material
US20150233249A1 (en) * 2014-02-20 2015-08-20 Hamilton Sundstrand Corporation Propeller blade and method
US9920629B2 (en) * 2014-02-20 2018-03-20 Hamilton Sundstrand Corporation Propeller blade and method
US10626884B2 (en) 2016-12-09 2020-04-21 Hamilton Sundstrand Corporation Systems and methods for making airfoils
US10710705B2 (en) 2017-06-28 2020-07-14 General Electric Company Open rotor and airfoil therefor
US11346363B2 (en) * 2018-04-30 2022-05-31 Raytheon Technologies Corporation Composite airfoil for gas turbine
FR3107719A1 (fr) * 2020-03-02 2021-09-03 Safran Aircraft Engines Texture fibreuse pour aube de turbomachine en matériau composite
WO2021176162A1 (fr) * 2020-03-02 2021-09-10 Safran Aircraft Engines Texture fibreuse pour aube de turbomachine en materiau composite
US11686203B2 (en) 2020-03-02 2023-06-27 Safran Aircraft Engines Fibrous texture for turbine engine blade made of composite material
US11846192B1 (en) 2023-04-21 2023-12-19 General Electric Company Airfoil assembly with a trunnion and spar
US12037938B1 (en) 2023-06-30 2024-07-16 General Electric Company Composite airfoil assembly for a turbine engine

Also Published As

Publication number Publication date
RU2533384C2 (ru) 2014-11-20
EP2516263A1 (fr) 2012-10-31
JP2013514941A (ja) 2013-05-02
BR112012015167A2 (pt) 2020-08-18
CN102666277A (zh) 2012-09-12
JP5922032B2 (ja) 2016-05-24
BR112012015167B1 (pt) 2021-08-10
WO2011083250A1 (fr) 2011-07-14
CN102666277B (zh) 2015-04-01
FR2954271A1 (fr) 2011-06-24
CA2784740C (fr) 2018-02-20
CA2784740A1 (fr) 2011-07-14
EP2516263B1 (fr) 2014-09-10
US20130017093A1 (en) 2013-01-17
FR2954271B1 (fr) 2012-02-17
RU2012131274A (ru) 2014-01-27

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